Machining of ceramic materials

ABSTRACT

Milling strategies for machining dental ceramic materials are provided that reduce milling time while maintaining strength, accuracy and marginal integrity.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/562,348, filed Sep. 18, 2009, which is a continuation in part of U.S.patent application Ser. No. 11/935,203, filed Nov. 5, 2007, which is ofdivision of U.S. patent application Ser. No. 10/913,095, filed Aug. 6,2004, now U.S. Pat. No. 7,316,740, which claims priority to GermanPatent Application Serial No. 103 36 913.9, filed Aug. 7, 2003, all ofwhich are herein incorporated by reference in their entirety.

FIELD OF THE INVENTION

The invention relates to lithium silicate materials which can be easilyshaped by machining and subsequently converted into shaped products withhigh strength.

BACKGROUND OF THE INVENTION

There is an increasing demand for materials which can be processed intodental restorative products, such as crowns, inlays and bridges, bymeans of computer controlled milling machines. Such CAD/CAM methods arevery attractive as they allow to provide the patient quickly with thedesired restoration. A so-called chair-side treatment is thus possiblefor the dentist.

However, materials suitable for processing via computer aideddesign/computer aided machining (CAD/CAM) methods have to meet a veryspecific profile of properties.

First of all, they need to have in the finally prepared restorationappealing optical properties, such as translucence and shade, whichimitate the appearance of the natural teeth. They further need to showhigh strength and chemical durability so that they can take over thefunction of the natural tooth material and maintain these propertiesover a sufficient period of time while being permanently in contact withfluids in the oral cavity which can even be aggressive, such as acidicin nature.

Secondly and very importantly, it should be possible to machine them inan easy manner into the desired shape without undue wear of the toolsand within short times. This property requires a relatively low strengthof the material and is therefore in contrast to the desired propertiesmentioned above for the final restoration.

The difficulty of combining the properties of low strength in the stageof the material to be processed and a high strength of the finalrestoration is reflected by the known materials for a CAD/CAM processingwhich are in particular with respect to an easy machinabilityunsatisfactory.

DE-A-197 50 794 discloses lithium disilicate glass ceramics which areprimarily intended to be shaped to the desired geometry by ahot-pressing process wherein the molten material is pressed in theviscous state. It is also possible for these materials to be shaped bycomputer aided milling processes. However, it has been shown that themachining of these materials results in a very high wear of the toolsand very long processing times. These disadvantages are caused by thehigh strength and toughness primarily imparted to the materials by thelithium disilicate crystalline phase. Moreover, it has been shown thatthe machined restorations show only a poor edge strength. The term “edgestrength” refers to the strength of parts of the restoration having onlya small thickness in the range of few 1/10 mm.

Further approaches of achieving easy machinability together with a highstrength of the final restoration have also been made. EP-B-774 993 andEP-B-817 597 describe ceramic materials on the basis of Al₂0₃ or ZrO₂which are machined in an unsintered state which is also referred to as“green state”. Subsequently, the green bodys are sintered to increasethe strength. However, these ceramic materials suffer from a drasticalshrinkage of up to 50% by volume (or up to 30% as linear shrinkage)during the final sintering step. This leads to difficulties in preparingthe restorations with exactly the dimensions as desired. The substantialshrinkage represents a particular problem if complicated restorationsare manufactured, such as a multi-span bridge.

From S. D. Stookey: “Chemical Machining of Photosensitive Glass”, Ind.Eng. Chem., 45, 115-118 (1993) and S. D. Stookey: “PhotosensitivityOpacifiable Glass” U.S. Pat. No. 2,684,911 (1954) it is also known thatin lithium silicate glass ceramics a. metastable phase can be formed atfirst. For example in photosensitive glass ceramics (Fotoform®,FotoCeram®) Ag-particles are formed using UV-light. These Ag-particlesserve as crystallization agent in a lithium metasilicate phase. Theareas which were exposed to light are in a subsequent step washed out bydiluted HF. This procedure is possible since the solubility of thelithium metasilicate phase in HF is much higher than the solubility ofthe parent glass. The glass portion remaining after said solubilizingprocess (Fotoform®) can be transferred into a lithium disilicate glassceramic (FotoCeram®) by an additional heat treatment.

Also investigations of Borom, e.g. M.-P. Borom, A. M. Turkalo, R. H.Doremus: “Strength and Microstructure In Lithium DisilicateGlass-Ceramics”, J. Am. Ceream. Soc., 58, No. 9-10, 385-391 (1975) andM.-P. Borom, A. M. Turkalo, R. H. Doremus: “Verfahren zum Herstellen vonGlaskeramiken” DE-A-24 51 121 (1974), show that a lithium disilicateglass ceramic can in the first instance crystallize in varying amountsas metastable lithium metasilicate phase. However, there also existcompositions which crystallize in the form of the disilicate phase fromthe beginning and the metasilicate phase is not present at all. Asystematic investigation of this effect has not become known. From theinvestigations of Borom it is also known that the glass ceramic whichcontains lithium metasilicate as the main phase has a reduced strengthcompared to the one of a glass ceramic which only contains a lithiumdisilicate phase.

Thus, the prior art materials show a couple of shortcomings. It is,therefore, an object of the present invention to eliminate thesedisadvantages and in particular to provide a material which, above all,can be easily shaped by computer-aided milling and trimming processesand can subsequently be converted into high-strength dental productswhich also display a high chemical durability and excellent opticalproperties and exhibit a drastically reduced shrinkage during said finalconversion.

SUMMARY OF THE INVENTION

This object is achieved by the lithium silicate glass ceramic materialof the present invention.

The invention also relates to a lithium disilicate material, dentalarticles comprising lithium disilicate, processes for manufacturing oflithium silicate ingots and blanks convertible to lithium disilicate andtheir uses for fabrication of dental restorations utilizing heat (hot)pressing and CAD/CAM, a lithium silicate glass and uses thereof, andmethods for manufacturing lithium silicate dental articles and dentalrestorations.

In particular this invention is related to methods of mass-production ofdental restorations using lithium silicate blanks and at least 4-axis orgreater CNC machines. More specifically this invention is related tomilling strategies especially useful for machining lithium silicateblanks using 5-axis or greater CNC machines equipped with robotic andautomated loading features.

Additional aspects of the embodiments of the invention are directed to amethod of reducing the time for machining a dental ceramic blank,wherein the fracture toughness (K_(Ic)) and the flexural strength(α_(f)) of the dental ceramic material are known, comprising calculatingan estimate of the maximal surface critical flaw size and an estimate ofthe maximal volume critical flaw size of the dental ceramic using thefollowing formula:c=(K _(Ic)/σ_(f))²

wherein:

-   -   c is the maximal surface critical flaw size; and    -   2c is the maximal volume critical flaw size.

Further aspects of the method include implementing a machining strategyusing a series of diamond tools, wherein the diamond tools compriseembedded diamonds; wherein the machining strategy comprises rough,intermediate and fine machining steps; wherein each step comprises atool path and machining parameters; wherein the tool path and machiningparameters are carried out by at least one of the series of diamondtools; wherein the grain size of the embedded diamonds is larger thanapproximately the estimated maximal size of the surface critical flawand smaller than approximately the estimated maximal size of the volumecritical flaw.

According to a further embodiment of the present invention, a machiningstrategy for machining a dental ceramic blank into a dental article isprovided, wherein the fracture toughness (K_(Ic)) and the flexuralstrength (σ_(f)) of the dental ceramic material are known, comprisingcalculating an estimate of the maximal surface critical flaw size and anestimate of the maximal volume critical flaw size of the dental ceramicusing the following formula:c=(K _(Ic)/σ_(f))²

wherein:

-   -   c is the maximal surface critical flaw size and    -   2c is the maximal volume critical flaw size.

Further aspects of the method include determining the number ofmachining steps needed to mill the dental ceramic blank into the dentalarticle by comparing the corresponding CAD file to the chosen blankgeometry and material properties, defining milling parameters andcomputing the tool path for each machining step. Tool paths andmachining parameters for all the machining steps required to mill adental article are stored as a file called hereinafter CAM file. CAMfile comprises specific commands and GO codes for a given CNC machine toexecute all the required machining steps and associated tool paths tomill a dental article. In one of the preferred embodiments this is doneby the process of mapping the shape to be milled (i.e. CAD file) onto aselected blank to establish the volume to be removed, which is thenseparated into regions requiring different accuracy and surfaceroughness. The regions are allocated to one or more of a roughmachining, intermediate machining and fine machining step. The specifictool path is then calculated for each of the allocated machining stepsand converted as a series of commands (GO codes) for CNC control unit(controller). Each machining step comprises tool path, machiningparameters and tool selection and is implemented using at least one of aseries of diamond tools for each machining step, wherein the diamondtools comprise embedded diamonds; wherein the grain size of the embeddeddiamonds is larger than approximately the estimated maximal value of thesurface critical flaw size and smaller than approximately the estimatedmaximal value of the volume critical flaw size. Machining parameterscomprise CNC machine (milling unit of a CAD/CAM system) settingscritical for its operation and tool path computations such as RPM(revolutions per minute), feed rate (mm/min), tool geometry or lengthand diameter (mm), diamond tool grain size or grit (microns), depth ofcut or lateral lining (microns), feed per revolution (microns). Depth ofcut is normally set to be lower than the grain size of the embeddeddiamonds. The following principals are unique and critical for themilling strategy of the present invention: depths of cut are selectedfor fine machining to be less than the estimated maximal surfacecritical flaw size while depth of cut for rough machining is roughlyequal or slightly larger than the estimated maximal surface criticalflaw size. Feed rate per revolution is nearly always (except for special“Prep_fini” fine finishing steps to finesse the margin of therestoration) smaller than the depth of cut to minimize contact stresseson the tool, which include, work piece interface, shear (pull-out)stresses on embedded diamonds and tool wear. The aforementioned millingstrategy, principals and approaches implemented as software instructionsfor selecting and computing optimal machining parameters and tool pathsspecific for each given material is hereinafter called template, forexample lithium silicate template or leucite glass-ceramic template.

Milling with diamond tools (grinding) is quite different from millingwith fluted tools (cutting). Diamond tools either comprise a coatingwith embedded diamonds or a matrix with embedded diamonds dispersedthrough the whole thickness of a tool. In both cases, embedded diamondsare characterized by a grain size distribution, range of grain sizes,grit size, and/or average grain size. Very often embedded diamonds arereferred to as diamond grit. During machining, high contact stresses aregenerated on the interface between a work-piece and a tool. With allthings being equal, it is beneficial to minimize the level of thosestresses while maximizing material removal rate. The local stresscondition on the milled surface in immediate contact with the diamondtool is very complex and is characterized by a stress tensor with allnine components changing in time. When a chip of material is cleavedaway by the advancing diamond, the strain energy is released and whenthe next diamond hits the milled surface the stress begins building upagain. It should be noted that many of these stress tensor componentsare parasitic and do not contribute to the effective machining processby cleaving off chips of material, but rather to tool wear by diamondpull-out. The volume of material to be removed is provided bysubtracting the net shape of the dental article to be milled from theblank shape and separating it into regions requiring different materialremoval rates, accuracy and surface roughness. The regions are allocatedto one or more of a rough, intermediate and fine machining step alongwith a specific tool path, which is calculated for each of the allocatedmachining steps. The purpose of the rough machining step is toapproximate to the near net shape in the minimum amount of time(accuracy and surface roughness are not important). Intermediatemachining is utilized to get closer to the net shape and is sufficientwhere surface roughness and accuracy are not so important (e.g., such aswith the internal lateral surfaces of the coping or crown, which will beultimately sealed by cement or adhesive). Fine machining is required forhigh accuracy and for a fine surface finish, such as at the margin ofthe restoration underside, which will carry most of the global loading.It was found that there is a synergy between simultaneous 5-axis millingand the use of conical diamond tools having round tips, allowing anoptimal “angle of attack” to avoid introduction of dangerous, strengthlimiting flaws and allow more aggressive grinding. As a result, feedrates and material removal rates are maximized without noticeablecompromise in strength. The rough, intermediate and fine machining stepsare further dependent on the difference in volume of the dental ceramicblank and the machined net shape of the dental article and furtherdependent on the final roughness and accuracy of the machined net shape.

In further aspects, the dental article may comprise an inside surface,an outside surface and a preparation line and the machining steps mayinclude one or more of the following: drilling an inside surface of theceramic blank, milling an inside surface of the ceramic blank, millingthe preparation line inside the ceramic blank, milling the preparationline outside the ceramic blank, drilling the outside surface of theceramic blank, and milling the outside surface of the ceramic blank.Machining may include drilling, milling, cutting, grinding or acombination thereof.

In other aspects, the tools used herein may have diameters that rangefrom approximately 0.5 mm to approximately 3.0 mm. The grain size of thediamonds embedded in the tools may range from approximately 60 micronsto approximately 150 microns, or from about 90 to about 130 microns.

In additional aspects, the machining parameters may include toolspecifications, revolutions per minute, linear speeds, feed rate(mm/min), feed per rotation (microns), depth of cut (microns) andmaterial removal rate. Possible ranges for revolutions per minute (RPM)are from 30,000 to 100,000 revolutions per minute and preferably from30,000 to 60,000 revolutions per minute. Possible ranges of the feedrate include approximately 500 mm/min to approximately 5000 mm/min. Thedepth of cut may range from approximately 10 microns to approximately150 microns, preferably from about 10 microns to about 130 microns. Itis preferable that the depth of cut is smaller than the grain size ofthe embedded diamonds and that the feed per rotation is smaller than thedepth of cut. It is further preferable that the depth of cut is smallerthan the estimated maximal value of the surface critical flaw size forfine machining and larger than the estimated maximal value of thesurface critical flaw size for rough machining. The series of tools mayinclude conical diamond tools having round tips and coated with diamondgrains having different sizes. The conical form gives the grindingdevice much more rigidity against vibrations. The machining strategy incombination with the series of diamond tools reduce machining time whilemaintaining strength, accuracy and marginal integrity. For certain typesof machinable ceramic materials carbide tools may also be used.

In further aspects, the machining process includes the use of computerfiles, wherein a first computer file comprises the specifications of thedental article to be machined and wherein the machining tool path isdetermined from the specifications in the first computer file. Thedental ceramic blank comprises a geometry and material properties andthe specifications of the first computer file are compared with thegeometry and material properties of the dental ceramic blank. Theprocess further includes mapping the specifications of the firstcomputer file onto the dental ceramic blank to determine the volume ofmaterial to be removed, separating the volume of material to be removedinto regions comprising degrees of accuracy and surface roughness. Theregions are machined by rough machining, intermediate machining and/orfine machining steps. Each rough, intermediate and fine machining stepcomprises at least one tool path, machining parameters and toolselection. The tool path is calculated and converted into a series ofcommands in a second computer file. The second computer file, machiningparameters and tool selection are provided to a milling machine.

In still further aspects, the dental ceramic blank may comprise lithiumsilicate having a strength in the range from approximately 80 toapproximately 180 MPa and a fracture toughness in the range fromapproximately 0.7 to approximately 1.3 MPa·m^(0.5). Additional strengthranges include approximately 90 to approximately 150 MPa. The flexuralstrength may be selected from flexural strength per ISO6872, 3-pointbend strength, 4-point bend strength, biaxial flexure strength (alsoknown as biaxial strength).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a principle temperature profile of a process according tothe invention starting from the melt via lithium metasilicate to lithiumdisilicate.

FIG. 2 shows a DSC-plot of a lithium silicate material according toexample 13.

FIG. 3 shows a high temperature XRD of a lithium silicate materialaccording to example 13, in form of a bulk glass sample.

FIG. 4 shows an XRD for phase analysis of a lithium silicate materialaccording to example 13 after nucleation and first crystallization.

FIG. 5 shows an SEM-micrograph, back scattered electrons, of a lithiumsilicate material according to example 13 after nucleation and firstcrystallization.

FIG. 6 shows an XRD for phase analysis of a lithium silicate materialaccording to example 13 which was subjected to nucleation, firstcrystallization and second crystallization conditions, and

FIG. 7 shows an SEM-micrograph, back scattered electrons, of a lithiumsilicate material according to example 13 which was subjected tonucleation, first crystallization and second crystallization conditionsand has an etched surface.

FIG. 8 shows a schematic diagram of a block of material during anembodiment of a milling operation of the present invention.

FIG. 9 shows an SEM-micrograph of a grinding tool used in an embodimentof the milling strategy of the present invention.

FIG. 10 shows an SEM-micrograph of a grinding tool used in an embodimentof the milling strategy of the present invention.

FIG. 11 shows an SEM-micrograph of a grinding tool used in an embodimentof the milling strategy of the present invention.

FIG. 12 shows an SEM-micrograph of a cylindrical grinding tool used inthe Sirona CEREC system.

FIG. 13 shows an SEM-micrograph of a step grinding tool used in theSirona CEREC system.

FIG. 14 a shows a perspective view of the grinding tool of FIG. 9.

FIG. 14 b shows a cross-sectional view of the grinding tip of thegrinding tool of FIG. 14 a.

FIG. 14 c shows a cross-sectional view of the grinding tool of FIG. 14a.

FIG. 15 a shows a perspective view of the grinding tool of FIG. 10.

FIG. 15 b shows a cross-sectional view of the grinding tip of thegrinding tool of FIG. 15 a.

FIG. 15 c shows a cross-sectional view of the grinding tool of FIG. 15a.

FIG. 16 a shows a perspective view of the grinding tool of FIG. 11.

FIG. 16 b shows a cross-sectional view of the grinding tip of thegrinding tool of FIG. 16 a.

FIG. 16 c shows a cross-sectional view of the grinding tool of FIG. 16a.

FIG. 17 shows a tool path for a machining step involving 5-axis drillingwith a tapered tool.

FIG. 18 shows a tool path for a machining step involving 5-axis millingwith a tapered tool.

DETAILED DESCRIPTION OF THE INVENTION

It should be mentioned that any references, including patents, patentapplications and published articles that are cited herein areincorporated by reference in their entirety. Any word used herein inplural form may also include singular forms of the word and any wordused in singular form herein may also include plural forms of the word.

It has surprisingly been shown that by using a starting glass of a veryspecific composition and a specific process it is possible to providethe glass ceramic according to the invention which has metastablelithium metasilicate (Li₂SiO₃) as main crystalline phase rather thanlithium disilicate (Li₂Si₂O₅). This lithium metasilicate glass ceramichas a low strength and toughness and hence can be easily machined intothe shape of even complicated dental restorations, but can after suchmachining be converted by a heat treatment into a lithium disilicateglass ceramic product with outstanding mechanical properties, excellentoptical properties and very good chemical stability thereby undergoingonly a very limited shrinkage.

The lithium silicate glass ceramic material according to the inventioncomprises the following components

Component Wt. % SiO₂ 64.0-73.0 Li₂O 13.0-17.0 K₂0 2.0-5.0 Al₂O₃ 0.5-5.0P₂O₅ 2.0-5.0

and comprises lithium metasilicate as main crystalline phase.

Another preferred embodiment of the present invention is formed by asilicate glass ceramic material as described above which is formed in aprocess which includes a step wherein lithium metasilicate as maincrystalline phase is produced.

It is preferred that the lithium silicate material of the presentinvention further comprises the following additional componentsindependently from each other

Component Wt. % ZnO 0.5-6.0, preferably 2.0-6.0 Na₂O 0.0-2.0 Me^(II)O0.0-7.0, preferably 0.0-5.0 ZrO₂ 0.0-2.0 colouring and fluorescent0.5-7.5 metal oxides

with Me^(II)O being one or more members selected from the groupconsisting of CaO, BaO, SrO and MgO.

A lithium silicate material which comprises the following components,independently of one another, in the following amounts is particularlypreferred:

Component Wt. % SiO₂ 65.0-70.0 Li₂O 14.0-16.0 K₂O 2.0-5.0 Al₂O₃ 1.0-5.0P₂O₅ 2.0-5.0 ZnO 2.0-6.0 Na₂O 0.1-2.0 Me^(II)O 0.1-7.0, preferably0.1-5.0 ZrO₂ 0.1-2.0 coloring and fluorescent 0.5-3.5 metal oxideswith Me^(II)O being one or more members selected from the groupconsisting of CaO, BaO, SrO and MgO, and with the metal of the one ormore coloring and fluorescent metal oxides being preferably selectedfrom the group consisting of Ta, Tb, Y, La, Er, Pr, Ce, Ti, V, Fe andMn.

The phrase “ . . . independently from each other . . . ” means that atleast one of the preferred amounts is chosen and that it is thereforenot necessary that all components are present in the preferred amounts.

As colouring components or fluorescent components for example oxides off-elements may be used, i.e. the list of metals given above is not to beseen as terminal. The colouring or fluorescent components ensure thatthe colour of the final dental product matches that of the natural toothmaterial of the patient in question.

In the above composition P₂O₅ acts as a nucleation agent for the lithiummetasilicate crystals and a concentration of at least 2 wt % is requiredfor the necessary nucleation. Instead of P₂O₅, other nucleation agentsare also possible, e.g. compounds of the elements Pt, Ag, Cu and W.

In addition to the components mentioned above the glass ceramic mayfurther comprise additional components to enhance the glass technicalprocessability. Such additional components may therefore be inparticular compounds such as B₂O₃ and F which in general amount to 0 to5.0% by weight.

A lithium silicate material as described above is particularly preferredwhich comprises 67.0 to 70.0 wt % of SiO₂.

It has surprisingly been shown that a specific volume portion of lithiummetal silicate should be present to achieve excellent processingproperties. Thus, it is further preferred that the lithium metasilicatecrystalline phase forms 20 to 50 vol % and in particular 30 to 40 vol %of the lithium silicate material. Such a part of the volume leads to thecrystals being present rather remote from each other and hence avoids atoo high strength of the lithium silicate material.

The lithium metasilicate crystals are preferably of lamellar or plateletform. This leads to a very good machinability of the lithium silicatematerial without use of high energy and without uncontrolled breaking.The latter aspect of uncontrolled breaking is for example known fromglasses which are generally unsuitable for machining. It is assumed thatthe preferred morphology of the lithium metasilicate crystals is alsoresponsible for the surprisingly high edge strength of products, e.g.complicated dental restorations, can be made from the lithium silicatematerial according to the invention.

The lithium silicate material according to the invention preferably isin the form of a blank. The blank usually takes the form of a smallcylinder or a rectangular block. The exact form depends on the specificapparatus used for the desired computer-aided machining of the blank.

After the machining, the lithium silicate material according to theinvention has preferably the shape of a dental restoration, such as aninlay, an onlay, a bridge, an abutment, a facing, a veneer, a facet, acrown, a partial crown, a framework or a coping.

A lithium disilicate material which is formed in a process whichincludes a step wherein a phase comprising primarily crystalline lithiummetasilicate is produced, the lithium metasilicate being subsequentlyconverted to lithium disilicate forms a preferred embodiment of theinvention.

A dental product made from lithium disilicate, said lithium disilicatebeing formed in a process which includes a step wherein a phasecomprising primarily crystalline lithium metasilicate is produced, thelithium metasilicate being subsequently converted to lithium disilicateforms another preferred embodiment of the present invention.

A blank of lithium silicate glass ceramic material according to theinvention is preferably prepared by a process which comprises

-   -   (a) producing a melt of a starting glass containing the initial        components SiO₂, Li₂O, K₂O, Al₂O₃ and P₂O₅ as the main        components,    -   (b) pouring the melt of the starting glass into a mould to form        a starting glass blank and cooling the glass blank to room        temperature,    -   (c) subjecting the starting glass blank to a first heat        treatment at a first temperature to give a glass product which        contains nuclei suitable for forming lithium metasilicate        crystals,    -   (d) subjecting the glass product of step (c) to a second heat        treatment at a second temperature which is higher than the first        temperature to obtain the lithium silicate blank with lithium        metasilicate crystals as the main crystalline phase.

A process as described above, wherein the starting glass of step (a)further comprises ZnO, Na₂O, Me^(II)O, ZrO₂, and coloring andfluorescent metal oxides, with Me^(II)O being one or more membersselected from the group consisting of CaO, BaO, SrO and MgO ispreferred.

A process as described above, wherein the starting glass of step (a)comprises the following initial components, independently of oneanother, In the following amounts

Component Wt. % SiO₂ 65.0-70.0 Li₂O 14.0-16.0 K₂O 2.0-5.0 Al₂O₃ 1.0-5.0P₂O₅ 2.0-5.0 ZnO 2.0-6.0 Na₂O 0.1-2.0 Me^(II)O 0.1-7.0, preferably0.1-5.0 ZrO₂ 0.1-2.0 coloring and fluorescent 0.5-3.5 metal oxideswith Me^(II)O being one or more members selected from the groupconsisting of CaO, BaO, SrO and MgO and with the metal(s) of the one ormore coloring and fluorescent metal oxides being preferably selectedfrom the group consisting of Ta, Tb, Y, La, Er, Pr, Ce, Ti, V, Fe and Mnis even more preferred.

In step (a), a melt of a starting glass is produced which contains thecomponents of the glass ceramic. For this purpose a correspondingmixture of suitable starting materials, such as carbonates, oxides, andphosphates, is prepared and heated to temperatures of, in particular1300 to 1600° C., for 2 to 10 hours. In order to obtain a particularlyhigh degree of homogeneity, the glass melt obtained may be poured intowater to form glass granules and the glass granules obtained are meltedagain.

In step (b), the melt of the starting glass is poured into acorresponding mould, e.g. a steel mould, and cooled to room temperatureto give a glass product.

The cooling is preferably conducted in a controlled manner so as toallow a relaxation of the glass and to prevent stresses in the structureassociated with rapid temperature changes. As a rule, the melt istherefore poured into preheated moulds, e.g. of a temperature of about400° C. Subsequently, the product can slowly be cooled in a furnace toroom temperature.

In step (c) the starting glass product is subjected to a first heattreatment at a first temperature to cause formation of nuclei forlithium metasilicate crystals. Preferably, this first heat treatmentinvolves a heating of the glass product for a period of 5 minutes to 1hour at a first temperature of 450 to 550° C. In some cases it isconvenient to combine step b) and step c) in order to relax the glassarticle and nucleate the lithium metasilicate crystals in one singleheat treatment therefore a process as described above, wherein step (c)is replaced by modifying step (b) such that during the cooling process atemperature of about 450 to 550° C. is held for a period of about 5minutes to 50 minutes to produce the glass product which contains nucleisuitable for formation of the lithium metasilicate crystals during step(b) forms a preferred embodiment of the invention.

A process as described above, wherein in step (c) the first heattreatment comprises heating the starting glass blank to a temperature ofabout 450 to 550° C. for a period of about 5 minutes to 1 hour formsanother preferred embodiment of the invention.

Subsequently, the glass product comprising the desired nuclei is cooledto room temperature.

In the subsequent step (d), the glass product having the desired nucleiof Li₂SiO₃ is subjected to a second heat treatment at a secondtemperature which is higher than the first temperature. This second heattreatment results in the desired formation of lithium metasilicatecrystals as predominant and preferably as only crystalline phase andtherefore gives the lithium metasilicate glass ceramic according to theinvention. Preferably, this second heat treatment of step (d) comprisesheating the glass product which contains nuclei suitable for formationof lithium silicate crystals to a second temperature of about 600 to700° C. for a period of about 10 to 30 minutes.

The principle temperature profile of such a process is exemplified inFIG. 1. Already starting from the melt (1), i.e. at the end of step a)the temperature decreases for relaxation of the product in a temperaturerange of 500 to 450° C. (2). The temperature can then be brought to roomtemperature (solid line), step b), and afterwards be brought to atemperature of about 450 to 550° C. or can be kept in the temperaturerange of 450 to 500° C. (dotted line). In the region that is labeledwith (3), step c), nucleation occurs at a temperature of 450 to 550° C.and is influenced by P₂O₅. Then, the glass material can be heateddirectly to a temperature in the range of 600 to 700° C. and kept atsaid temperature (4) during which time lithium metasilicate forms, stepd). Subsequently the material can be cooled down (solid line) to e.g.about room temperature for grinding, milling or CAD-CAM processing andcan afterwards be brought to a temperature of about 700 to 950° C. orcan directly be brought to 700 to 950° C. (dotted line) at whichtemperature (5) the second crystallization occurs forming the lithiumdisilicate and where additional heat treatment or hot pressing can beundertaken.

Depending on the specific composition of a selected starting glass, itis possible for the skilled person by means of differential scanningcalorimetry (DSC) and x-ray diffraction analyses to determine suitableconditions in steps (c) and (d) to result in materials having thedesired morphology and size of the crystals of lithium metasilicate. Tofurther illustrate this process FIGS. 2 to 5 together with Tables I andII in the example section indicate how the relevant data were obtainedfor example 13 using said measurements and are therefore obtainable ingeneral. Moreover, these analyses allow also the identification ofconditions avoiding or limiting the formation of undesirable othercrystalline phases, such as of the high-strength lithium disilicate, orof cristobalite and lithium phosphate.

Subsequent to step (d), it is preferred to shape the obtained glassceramic. This is preferably effected by step (e), wherein the lithiummetasilicate glass ceramic is machined to a glass ceramic product of thedesired shape, in particular the shape of a dental restoration. Themachining is preferably carried out by trimming or milling. It isfurther preferred that the machining is controlled by a computer, inparticular by using CAD/CAM-based milling devices. This allows aso-called chair-side treatment of the patient by the dentist.

It is a particular advantage of the glass ceramic according to theinvention that it can be shaped by machining without the undue wear ofthe tools observed with the tough and high-strength prior art materials.This is in particular shown by the easy possibility to polish and trimthe glass ceramics according to the invention. Such polishing andtrimming processes therefore require less energy and less time toprepare an acceptable product having the form of even very complicateddental restorations.

Lithium disilicate dental restorations can be produced in many differentways. Commonly used by dental technicians are the CAD/CAM and the hotpressing technique. Dentists can use a CAD/CAM method (Cerec 2®, Cerec3®) to produce chair-side an all ceramic lithium disilicate restoration.The final result is always a dental restoration with lithium disilicateas the main crystalline phase. For this purpose, the blank can be alithium metasilicate glass ceramic according to the invention. The glassceramic according to the invention can therefore be processed in bothways, by CAD/CAM or by hot-pressing, which is very advantageous for theuser.

It is also possible to use for these purposes a corresponding lithiumsilicate glass which comprises nuclei suitable for formation of lithiummetasilicate crystals. This glass is a precursor of the lithiummetasilicate glass ceramic of the invention. The invention is alsodirected to such a glass. It is obtainable by the above process in step(c).

For manufacturing a dental restoration by the hot pressing technique alithium silicate glass ingot having nuclei for lithium metasilicate issubjected to a heat treatment of about 700 to 1200° C. to convert itinto a viscous state. The heat treatment will be conducted in a specialfurnace (EP 500®, EP 600®, Ivoclar Vivadent AG). The ingot is embeddedin a special investment material. During the heat treatment the ingotwill be crystallized. The main crystal phase is then lithium disilicate.The viscous glass ceramic flows under a pressure of 1 to 4 MPa into thecavity of the investment material to obtain the desired shape of thedental restoration. After cooling the investment mould to roomtemperature the lithium disilicate restoration can be divested by sandblasting. The framework can be further coated with a glass or a glassceramic by sintering or hot pressing technique to get the finalizeddental restoration with natural aesthetics.

An ingot which comprises the lithium silicate glass ceramic according tothe invention is subjected to a heat treatment of about 700 to 1200° C.to convert it into a viscous state. The heat treatment will be conductedin a special furnace (EP 500®, EP 600®, Ivoclar Vivadent AG). The glassceramic ingot is embedded in a special investment material. During theheat treatment the glass ceramic will be further crystallized. The maincrystal phase is then lithium disilicate. The viscous glass ceramicflows under a pressure of 1 to 4 MPa into the cavity of the investmentmaterial to obtain the desired shape of the dental restoration. Aftercooling the investment mould to room temperature the lithium disilicaterestoration can be divested by sand blasting. The framework can befurther coated with a glass or a glass ceramic by sintering or hotpressing technique to get the finalized dental restoration with naturalaesthetics.

For manufacturing a dental restoration by the CAD/CAM technique thelithium silicate or the lithium metasilicate blocks with lithiumdisilicate as possible minor crystalline phase having a strength ofabout 80 to 150 MPa can be easily machined in a CAM unit like Cerec 2®or Cerec 3® (Sirona, Germany). Larger milling machines such as DCSPrecimill® (DCS, Switzerland) are also suitable. The block is thereforepositioned in the grinding chamber by a fixed or integrated holder. TheCAD construction of the dental restoration is done by a scanning processor an optical camera in combination with a software tool. The millingprocess needs for one unit 10 to 15 minutes. Copy milling units such asCelay® (Celay, Switzerland) are also suitable for machining the blocks.First, a 1:1 copy of the desired restoration is fabricated in hard wax.The wax model is then mechanically scanned and 1:1 mechanicallytransmitted to the grinding tool. The grinding process is therefore notcontrolled by a computer. The milled dental restoration has to besubjected to a heat treatment to get the desired lithium disilicateglass ceramic with high strength and tooth like color. The heattreatment is conducted in the range of 700 to 900° C. for a period ofabout 5 to 30 minutes. The framework can be further coated with a glassor a glass ceramic by sintering or hot pressing technique to get thefinalized dental restoration with natural aesthetics.

Blocks with lithium disilicate as main crystalline phase can only begrinded in a large milling machine such as DCS Precimill® (DCS,Switzerland) due to the high strength and toughness of the glassceramic. The block is therefore positioned in the grinding chamber by afixed metal holder. The CAD construction of the dental restoration isdone by a scanning process in combination with a software tool. Anadditional heat treatment in the range of 700 to 900° C. could beconducted in order to close surface flaws which were induced by thegrinding process. The framework can be further coated with a glass or aglass ceramic by sintering or hot pressing technique to get thefinalized dental restoration with natural aesthetics.

It has further been shown that the easily machinable lithiummetasilicate glass ceramic according to the invention can be convertedinto a lithium disilicate glass ceramic product by a further heattreatment. The obtained lithium disilicate glass ceramic has not onlyexcellent mechanical properties, such as high strength, but alsodisplays other properties required for a material for dentalrestorations.

Thus, the invention also relates to a process for preparing a lithiumdisilicate glass ceramic product, which comprises (f) subjecting theLithium metasilicate glass ceramic according to the invention to a thirdheat treatment to convert lithium metasilicate crystals to lithiumdisilicate crystals.

In this step (f), a conversion of the metastable lithium metasilicatecrystals to lithium disilicate crystals is effected. Preferably, thisthird heat treatment involves a complete conversion into lithiumdisilicate crystals and it is preferably carried out by heating at 700to 950° C. for 5 to 30 minutes. The suitable conditions for a givenglass ceramic can be ascertained by conducting XRD analyses at differenttemperatures.

It was also found out that the conversion to a lithium disilicate glassceramic is associated with only a very small linear shrinkage of onlyabout 0.2 to 0.3%, which is almost negligible in comparison to a linearshrinkage of up to 30% when sintering ceramics.

A process as described above, wherein the lithium silicate blank has abiaxial strength of at least 90 MPa and a fracture toughness of at least0.8 MPam^(0.5) is preferred.

A process as described above, wherein the starting glass blank of step(b), the glass product containing nuclei suitable for forming lithiummetasilicate of step (c), or the lithium silicate blank with lithiummetasilicate as the main crystalline phase of step (d) is shaped to adesired geometry by machining or by hot pressing to form a shapedlithium silicate product is also preferred.

Such a process, wherein the shaped lithium silicate blank is a dentalrestoration is more preferred and a process wherein the dentalrestoration is an inlay, an onlay, a bridge, an abutment, a facing, aveneer, a facet, a crown, a partial crown, a framework or a coping iseven more preferred.

A process as described above, wherein the machining is performed bygrinding or milling forms a preferred embodiment of the invention,whereby a process wherein the machining is controlled by a computer iseven more preferred.

A process as described above but further comprising subjecting theshaped lithium silicate product to a third heat treatment at a thirdtemperature of about 700 to 950° C. for a period of about 5 to 30minutes is another aspect of the present invention and said process isparticularly preferred when the lithium silicate product subjected tothe third heat treatment comprises lithium metasilicate as the maincrystalline phase, and wherein the third heat treatment converts thelithium metasilicate crystals to lithium disilicate crystals as the maincrystalline phase of the dental restoration.

A process as described above wherein the lithium silicate productsubjected to the third heat treatment comprises the glass productcontaining nuclei suitable for forming lithium metasilicate crystals,and wherein lithium disilicate crystals are crystallized directly fromthe nuclei suitable for forming lithium metasilicate crystals is alsopreferred.

Another preferred embodiment of the present invention is a process asdescribed above, wherein the shrinkage that occurs during the third heattreatment is less than 0.5%, preferably less than 0.3%, by volume.

A process as described above which comprises shaping of a lithiumsilicate material to the desired geometry by hot pressing to produce thedental restoration is also an object of the invention, with a processfor manufacturing a dental restoration as described above beingpreferred wherein the hot pressing comprises subjecting the lithiumsilicate material to a heat treatment at a temperature of about 500 to1200° C. to convert the lithium silicate material into a viscous stateand pressing the viscous lithium silicate material under a pressure ofabout 1 to 4 MPa into a mould or dye to obtain the dental restorationwith a desired geometry.

A process as described above, wherein the lithium silicate materialsubjected to the heat treatment and pressing comprises lithiummetasilicate crystals which are converted into lithium disilicatecrystals during the heat treatment and pressing is more preferred.

A further preferred embodiment of the present invention is formed by aprocess as described above which comprises an increasing of strength andfracture toughness of the lithium silicate material.

A process for the manufacture of a dental restoration as described aboveis preferred, wherein the dental restoration has a biaxial strength ofat least 250 MPa and a fracture toughness of at least 1.5 MPam^(0.5).

A process for the manufacture of a dental restoration as described abovefurther comprising finishing the dental restoration to obtain a naturalappearance is preferred.

Same is true for a process as described above, wherein the finishingstep comprises applying a coating to the dental restoration by layeringwith powdered materials or by hot pressing a coating material onto theunfinished dental restoration.

A process as described above wherein the third heat treatment occursduring a firing of the layering materials or the hot pressing of thecoating material onto unfinished the dental restoration is even morepreferred.

Thus, a product is finally obtained which has all the beneficialmechanical, optical and stability properties making lithium disilicateceramics attractive for use as dental restorative materials. However,these properties are achieved without the disadvantages of theconventional materials when shaped by using a CAD/CAM based process, inparticular the undue wear of the milling and trimming tools.

Consequently, the invention also relates to a lithium disilicate glassceramic product which is obtainable by the above process for itspreparation and has lithium disilicate as main crystalline phase.Preferably, the lithium disilicate glass ceramic product according tothe invention is in the form of a dental restoration.

It is further preferred that in the lithium disilicate glass ceramic thelithium disilicate crystals form 60 to 80% by volume of the glassceramic.

The conversion of the lithium metasilicate glass ceramic according tothe invention to a lithium disilicate glass ceramic product isassociated with a surprisingly high increase in strength by a factor ofup to about 4. Typically, the lithium metasilicate glass ceramic of theinvention has a strength of about 100 MPa, and the conversion leads to alithium disilicate glass ceramic having a strength of more than 400 MPa(measured as biaxial strength).

The invention is also directed to a lithium silicate blank as describedabove, wherein the blank is combined with a holder, stem or retainer tofit into the milling machine or an adapter that fits into the millingmachine.

A lithium silicate blank as described above, wherein the holder is froma different material from the blank forms one embodiment of theinvention.

A lithium silicate material blank as described above, wherein the holderis made from an alloy, from a metal, from a glass ceramic or from aceramic forms a preferred embodiment of the invention.

A lithium silicate blank as described above, wherein the holder is madefrom the same material as the blank and is integral with the blank isanother embodiment of the invention.

A lithium silicate blank as described above, wherein the blank islabeled with information is another preferred embodiment.

Same is true for a lithium silicate blank as described above, whereinthe information on the blank comprises the material, the size and thetype of the shape, which is to be machined from the blank.

Another aspect of the present invention is directed to a method formanufacturing a lithium silicate restoration comprising preparinglithium silicate ingots or blanks as described above, and thereafteroverlaying a dental restoration with the lithium silicate material byheat (hot) pressing over the framework material or alternativelymachining (grinding or milling) a shape of overlay from the blank withall the necessary occlusal and cervical details and bonding the machinedlithium silicate overlay to a framework material.

A method for manufacturing a dental restoration as described abovewherein a dental framework is coated by hot pressing the lithiumsilicate blank onto the dental framework is one of the preferredembodiments. Other preferred methods comprise milling, staining/glazingand bonding overlay rather than conventional layering or heat pressingas described in WO 2007/028787 A1 by Schweiger et al. and also US PatentApplications 2006/0257823 and 2006/0257824 by Pfeiffer, all of which arehereby incorporated by reference herein in their entirety.

A method for manufacturing a dental restoration as described above,wherein the dental framework is a crown, a partial crown, a bridge, acoping, a veneer, a facing or an abutment is more preferred and such amethod, wherein the dental framework is made from a metal, an alloy, aceramic or a glass ceramic is even more preferred.

A method for manufacturing a dental restoration as described above,wherein the framework ceramic comprises zirconium oxide (zirconia),aluminum oxide (alumina), a zirconium mix oxide, an aluminium mix oxide,an alumina toughened zirconia, a zirconia toughened alumina or acombination thereof forms a particularly preferred embodiment of theinvention.

A method for manufacturing a dental restoration as described abovewherein the lithium silicate blank which is coated onto the frameworkcomprises lithium metasilicate crystals which are converted to lithiumdisilicate crystals, or the lithium silicate blank comprises nucleisuitable for forming lithium metasilicate crystals which crystallize aslithium disilicate crystals during the hot pressing of the lithiumsilicate blank onto the dental framework is another preferred object ofthe invention.

The invention is explained in more detail below on the basis of thefollowing non-limiting Examples.

EXAMPLES Examples 1 to 18 (Invention), 19 to 20 (Comparison) and 21 to23 (Invention)

A total of 18 different lithium metasilicate glass ceramic productsaccording to the invention as well as two ceramics for comparison withthe chemical compositions given in Table III were prepared by carryingout stages (a) to (d) of the process described above and finallyconverted to lithium disilicate glass ceramic products by step (e) ofthe process described above:

For this purpose samples of the corresponding starting glasses weremelted in a platinum-rhodium crucible at a temperature of 1500° C. andfor a period of 3 hours (a).

The glass melts obtained were then poured into steel moulds which werepreheated to 300° C. After 1 minute the glass blanks were transferredinto a furnace which was preheated to a temperature between 450 and 550°C. The exact values, KB T [° C.] and KB t [min], are given for eachsample in Table III. After this relaxation and nucleation process (b andc) the blocks were allowed to cool to room temperature. The nucleatedsamples were homogeneous and transparent.

The glass blanks, which contained nuclei for the crystallization, werethen subjected to step (d), i.e. the second heat treatment, tocrystallize lithium metasilicate, which means that the glass blanks wereexposed to a temperature of about 650° C. for a period of about 20minutes, except example 3, which was crystallized at 600° C.

The course of the crystallization was investigated by DSC-measurementand the resulting crystal phases were analyzed by XRD to identify theideal conditions for this heat treatment. “Ideal conditions” in thesense of the present invention are present in case the twocrystallization peaks of the meta- and the disilicate phase respectivelyare differing to such an extend that in the production process a neatdifferentiation can be implemented, i.e. when heating a sample to thefirst crystallization temperature it has to be secured that whenreaching the desired temperature within the sample the temperature atthe outer regions of the sample does not reach the secondcrystallization temperature, i.e. the bigger the temperature differenceof the first and the second crystallization temperature is the biggerthe sample mass can be.

To further illustrate the process FIG. 2 shows a DSC-plot of one of theexamples, example 13, a quenched and powdered glass sample, which washeated with a heating rate of 10 K/min. The crystallisation of lithiummetasilicate (1), the crystallisation of lithium disilicate (2) as wellas the glass transition temperature (3) and the temperature range (4)for the first crystallisation are clearly visible from said DSC-plot.

Also an example for the analysis of phase development by hightemperature XRD from the same example 13 is given. FIG. 3 thereforeshows the measurement of a bulk glass sample at a constant heating rateof 2 K/min. It can be recognized from said measurement that in this casethe crystallisation of the lithium metasilicate (1) occurs at atemperature of 510° C. and that in this case the resolution of thelithium metasilicate and the crystallization of the lithium disilicate(2) occur at a temperature of 730° C.

FIG. 4 represents a phase analysis by XRD of example 13 after nucleationat 500° C. for 7 min and first crystallisation at 650° C. and 20 min.

The corresponding data are summarized In Table I:

TABLE I 1 2 d-spacing in 0.1 nm d-spacing in 0.1 nm 3 of scan of patternIndex 4.628 4.690 LS 020 3.296 3.301 LS 111 2.708 LS 130 2.685 2.700 LS200 2.355 2.342 LS 131 2.333 2.331 LS 002

FIG. 5 shows an SEM-micrograph, backscattered electrons, of the sameexample having the same thermal history, with the surface being etchedwith 1% HF for 8 s. Clearly visible are holes that show former lithiummetasilicate crystals.

The resulting blocks were now ready for step (e), which means shapingthe lithium metasilicate glass ceramic to the desired shape, either bysaw cutting, or by milling it in a CAD-CAM milling machine (i.e. CEREC3®). The obtained lithium metasilicate glass ceramic blanks wereanalyzed for their machinability and their edge strength. 10 discs werecut from a rod with 12 mm diameter for biaxial strength measurements.The results of these analyses are given in Table IV. Ten more discs wereprepared and subjected to a third heat treatment (f).

In case the blanks contain colouring and fluorescent oxides the blocksin the state of the metasilicate appear to have a reddish or bluishcolour. This effect vanishes when the disilicate phase forms and theblanks turn to the colour that is desired.

Finally, the lithium metasilicate glass ceramic blanks were subjected toa second crystallization, step (f), at 850° C. for 10 min, exceptexample 3 which was crystallized at 830° C., i.e. the third heattreatment which is in general performed at temperatures of 700 to 950°C., preferably 820 to 880° C. and for a period of 5 to 30 minutes,preferably 5 to 20 minutes, to convert the lithium metasilicate intolithium disilicate.

The obtained products were analyzed for their crystal phases. To furtherillustrate the procedure the phase analysis for example 13 afternucleation at 500° C. for 7 min, first crystallization at 650° C. for 20min and second crystallization at 850° C. for 10 is shown in FIG. 6. Thecorresponding data are summarized in Table II.

TABLE II 1 2 d-spacing in 0.1 nm d-spacing in 0.1 nm 3 of scan ofpattern Index 5.369 5.420 LS2 110 3.986 3.978 LP 120 3.855 3.834 LP 1013.714 3.737 LS2 130 3.629 3.655 LS2 040 3.562 3.581 LS2 111 2.929 2.930LS2 131 2.901 2.908 LS2 200 2.379 2.388 LS2 002 2.346 2.35 LS2 221 2.2832.29 LS2 151 2.050 2.054 LS2 241

FIG. 7 shows an SEM-micrograph, backscattered electrons, of the sameexample having the same thermal history, with the surface being etchedwith 3% HF for 30 s leading to the glassy phase being etched out andleaving the lithium disilicate crystals.

In addition to the analysis in respect to crystal phases the sampleswere also analyzed in respect to their biaxial strength and chemicaldurability. Furthermore, their translucence was assessed. The resultsare also given in Table IV.

In table IV, the detected crystalline phases are designated as follows:

LS—lithium metasilicate

LS2—lithium disilicate

LP—lithium phosphate,

with the main phase being marked in bold type.

To gain information about the machinability tests were performed on aCerec® 3, with new tools being used for each test. A ‘Lego®-Minicube’served as a model which had to be milled from all compositions that weresubjected to this test and from a leucite-enforced glass ceramic of thename ProCAD® from Ivoclar Vivadent AG. The operating sequence was asfollows: First a blank of ProCAD® was milled, then a blank of theceramic to be tested was milled and after that again a ProCAD® blank wasmilled. The machinability was rendered “very good” in case the time thatwas required to mill the blank of the ceramic to be tested was below 95%of the time that was required to mill the ProCAD® blank. Times in therange of 95 to 105% of said time led to the mark “good” for themachinability, times in the range of 105 to 115% to “acceptable” andtimes above 115% to “poor”. The medium time required for the millingprocess was 14.0 minutes.

To compare the machinability of the test samples with another glassceramic a blank made according to the composition disclosed in DE 197 50794 was prepared and subjected to the test described above. After 15minutes the test was abandoned since only about 10% of the volume to bemilled was already milled and the tools used for milling were alreadyworn out, something that did not happen with any of the test samples.

The edge strength was determined as follows:

With a milling unit (CEREC 3®) blanks were milled to result inLego-minicubes. With a 1.6 mm cylindrical diamond cutter blind holeswere milled. The quality of said blind holes was determined by comparingthe area of the broken out edges with those of a reference sample(ProCAD®). The relation of the area of the broken out edges to the areaof the blind bore is an allocation for the edge strength.

An edge strength is considered to be “very good” in case the relation ofsaid areas is smaller than that of the reference, it is considered to be“good” in case the relations are about the same and it is considered tobe “acceptable” in case the area is bigger than 110% of the referencesample.

The chemical durability was determined according to ISO 6872, i.e. asloss of mass after 16 h in 4% acetic acid at 80° C.

“Good” means that the solubility according to said method is below 100pg/cm².

The strength was measured as biaxial strength according to ISO 6872 oras 3 point bending strength according to EN 843-1:

Bars of 12 mm diameter were casted and crystallized once. From thesebars 20 discs with a thickness of 1, 2 mm each were sawn. 10 of thesediscs were then smoothed and the surfaces of the discs were polishedusing SiC-paper of grain size 1000. Biaxial strength was measured as isdisclosed in ISO 6872. The other 10 discs were crystallized a secondtime at 800 to 900° C. to give the lithium disilicate phase. Thesesolidified samples were smoothed on both sides and the surfaces werepolished using SiC-paper of grain size 1000. Biaxial strength was thenmeasured according to ISO 6872.

By comparison bending strength was measured on bars with dimensions of25*3.5*3.0 mm were sawn out of a block of the lithium metasilicate glassceramic. These bars were smoothed to result in bars having dimensions of25*2.5*2.0 mm which were then polished using SiC-paper of grain size1000. The edges were also beveled with SiC-paper of grain size 1000. Thespan was 20 mm. The results are comparable to biaxial strength results.

In addition to this, fracture toughness was determined by applying aVickers indentation onto a polished surface and measuring the size ofthe flaws originating from the edges (Indentation Force Method . . .IF). This method is useful as comparative method but does not result inabsolute values. For comparison measurements were performed on notchedbending samples (SENB, SEVNB). For the lithium disilicate glass ceramicsfracture toughness values >2 MPam^(0.5) were obtained.

In Table II the values for the biaxial strength and the fracturetoughness of the samples having the disilicate phase, i.e. those samplesthat were crystallized twice, are given. In addition to that quotientsare given which give the ratio of the biaxial strength of the disilicatesystem to the biaxial strength of the metasilicate system (biaxialsolidification factor or Strength Increase Factor) or the ratio of thefracture toughness of the disilicate system to the fracture toughness ofthe metasilicate system (solidification factor K_(1C) or FractureToughness Increase Factor).

Translucence was determined after the second crystallization: a testpiece 16 mm diameter and having a thickness of 2 mm was prepared andpolished on both sides. The contrast value CR was determined accordingto BS 5612 (British Standard) using a spectral colorimeter (MinoltaCM-3700d). The determination of the contrast value consisted of twosingle measurements. The test piece to be analyzed is therefor placed infront of a black ceramic body having a reflexion of 4% at most andaccordingly in front of a white ceramic body having a reflexion of 86%at minimum which are then colourmetrically determined. Using highlytransparent test pieces reflexion/absorption is mainly caused by theceramic background whereas reflexion is caused by the test piece in casean opaque material is used. The ratio of reflected light on black groundto reflected light on white ground is the quantum for the contrastvalue, with total translucence leading to a contrast value of 0 andtotal opaquescence leading to a contrast value of 1. The samples wererated as follows:

extraordinary: CR<0.4

very good: 0.4<CR<0.5

good: 0.5<CR<0.6

acceptable: 0.6<CR<0.8

opaque: 0.8<CR.

TABLE III Expl No. 1 2 3 4 5 6 7 8 9 10 11 12 KBT 500 490 520 500 500500 500 500 500 500 520 500 [° C.] KBt 10 30 5 30 10 10 10 10 10 10 1010 [min] wt % SiO₂ 69.3 73.0 64.0 68.1 70.1 69.0 68.6 69.9 68.6 68.870.0 65.7 K₂O 4.3 4.4 4.2 4.2 4.5 4.3 4.3 4.4 2.0 5.0 5.0 4.1 Na₂O 2.0SrO 2.0 BaO 2.0 2.0 CaO 2.0 Li₂O 15.3 17.0 13.0 15.0 15.5 15.2 15.1 15.415.1 15.1 15.0 14.5 Al₂O₃ 1.1 1.1 4.0 5.0 1.1 1.1 1.1 1.1 3.0 1.1 1.11.1 P₂O₅ 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 5.0 3.8 2.0 3.8 MgO 1.0 0.0 1.00.0 5.0 1.0 1.0 1.0 0.0 1.0 0.9 1.0 ZrO₂ 2.o 1.0 ZnO 5.2 0.7 6.0 3.9 0.03.6 4.1 2.4 4.3 3.2 6.0 2.8 TiO₂ V₂O₅ Fe₂O₃ MnO₂ CeO₂ 2.0 0.5 Y₂O₃ La₂O₃0.5 Pr₂O₃ 1.0 Ta₂O₅ 1.5 Tb₄O₇ 1.5 Er₂O₃ 1.0 100.0 100.0 100.0 100.0100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 Expl No. 13 14 15 16 1718 19 20 KBT 500 500 500 500 500 500 500 500 [° C.] KBt 7 7 7 10 20 1010 30 [min] wt % SiO₂ 67.4 68.4 65.0 70.0 70.0 67.8 68.3 67.7 K₂O 4.02.7 2.0 4.4 3.8 4.1 4.3 4.2 Na₂O 0.1 1.0 0.1 0.1 0.1 0.1 SrO 2.0 BaO 2.0CaO 1.0 Li₂O 14.8 15.0 14.0 16.0 16.0 15.0 15.1 14.9 Al₂O₃ 1.1 3.0 4.11.8 1.1 1.1 0.0 0.0 P₂O₅ 3.8 3.5 3.8 3.8 3.8 3.8 3.8 3.8 MgO 0.5 0.1 0.00.3 0.1 0.1 1.0 1.0 ZrO₂ 0.1 0.1 0.1 0.1 0.1 0.1 ZnO 4.7 5.2 4.0 2.0 4.54.8 5.1 5.0 TiO₂ 1.6 V₂O₅ 0.2 Fe₂O₃ 0.2 MnO₂ 0.2 0.5 CeO₂ 2.0 1.0 0.41.0 0.4 0.5 Y₂O₃ 2.4 La₂O₃ 0.3 1.0 0.1 0.1 0.3 3.4 Pr₂O₃ Ta₂O₅ Tb₄O₇ 0.50.5 0.5 Er₂O₃ 0.3 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0

TABLE IV Ex. No. 1 2 3 4 5 6 7 8 9 10 phases present after 1st LS LS,LS2 LS LS LS, LS2 LS LS LS, LS2 LS LS crystallisation phases presentafter 2nd LS2, LP LS2, LP LS2, LP LS2, LP LS2, LP lS2, LP LS2, LP LS2,LP LS2, LP LS2, LP crystallisation biaxial strength after 2nd 359 424250 314 324 472 426 404 356 319 crystallisation biaxial solidificationfactor 3.0 2.4 2.5 3.4 2.4 3.5 3.5 2.3 3.2 2.7 (Strength IncreaseFactor) K1C [MPm^(0.5)] after 2nd 1.6 2.2 1.9 1.9 1.8 2.3 1.8 2.4 1.91.8 crystallisation K1C solidification factor 1.8 1.7 2.6 2.5 1.6 2.42.0 1.9 1.9 1.8 (K_(1C) Increase Factor) grinding time in 93% 103% 95%89% 98% 93% 94% 105% 94% 94% comparison to ProCAD Machinability verygood good very good very good good very good very good good very goodvery good edge strength Good very good good good good good acceptablegood acceptable good Translucency very good n.m. n.rn. n.m. n.m. extra-n.m. n.m. acceptable n.m. ordinary chemical durability Good good goodgood good good good good good good (ISO 6872) Ex. No. 11 12 13 14 15 1617 18 19 20 phases present after 1st LS, LS2 LS LS LS LS LS LS LS LS2LS2 crystallisation phases present after 2nd LS2, LP LS2, LP LS2, LPLS2, LP LS2, LP LS2, LP LS2, LP LS2, LP LS2, LP LS2, LP crystallisationbiaxial strength after 2nd 301 354 381 389 342 329 420 387 440 405crystallisation biaxial solidification factor 1.7 2.9 3.0 3.1 2.6 2.93.2 3.4 2.2 2.1 (Strength Increase Factor) K1C [MPm^(0.5)] after 2nd 2.12.0 1.9 2.0 1.8 1.7 2.1 1.9 1.8 1.9 crystallization K1C solidificationfactor 1.6 1.9 2.1 1.8 2.0 1.6 2.2 1.9 1.0 1.5 (K_(1C) Increase Factor)grinding time in 115% 98% 90% 91% 94% 100% 95% 94% 119% 129% comparisonto ProCAD Machinability Acceptable very good very good very good verygood good good very good poor poor edge strength Good acceptable verygood very good very good very good very good good good good translucencyn.m. n.m. n.m. n.m. n,m. n.m, n,m. n.m. n.m. n.m. chemical durabilityGood good good good good good good good good good (ISO 6872)

The data in Table II show that the lithium metasilicate glass ceramicscombine a very good machinability and high edge strength with the easypossibility to convert them by a simple heat treatment into lithiumdisilicate glass ceramics which have a very high bending strength aswell as an excellent chemical durability and good translucence, all ofwhich being properties which make them very attractive as materialsuseful for the manufacture of dental restorations.

In the following some examples are described in more detail:

Example 1

The glass was molten at a temperature of 1500° C. for 3 hours and wasthen poured into steel moulds which were preheated to 300° C. After oneminute the glass bars were transferred into a cooling furnace and weretempered at 500° C. for 10 minutes and then cooled to room temperature.

The glass was homogeneous and transparent.

Following the glass bar was subjected to a first crystallization at 650°C. for a period of 20 minutes.

From the such ceramized bar, discs were sawn out of a round bar, andbiaxial strength was measured. The phase content was analyzed via XRD(X-ray diffraction). Lithium metasilicate was the only phase that wasdetected. Biaxial strength was 119+/−25 MPa.

Also the milling time of test bodys was measured. The milling time ofthe test body was one minute below that of ProCAD®, which was used asreference.

The edge strength was good.

Additional 10 discs were subjected to a second crystallization at 850°C. for a period of 10 minutes and biaxial strength and fracturetoughness were measured.

Biaxial strength was 359+/−117 MPa which correlates to a StrengthIncrease Factor of 3.0.

Fracture toughness (IF) was 1.6 MPam^(0.5).

Translucence was very good.

The chemical stability according to ISO 6872 (4% acetic acid, 80° C., 16h) was 37 pg/cm².

Example 6

Glass bars were produced according to example 1. The glass again washomogeneous and transparent.

The first crystallization was performed at 650° C. for a period of 20minutes.

Lithium metasilicate was determined to be the main phase with traces oflithium disilicate also being present. Biaxial strength was 135+/−24MPa.

Again the milling time of a test body was measured. The milling time ofthe test body was one minute below that of ProCAD®, which again was usedas reference.

The edge strength was very good.

After a second crystallization which was performed according to example1 the biaxial strength was 472+/−85 MPa which correlates to a StrengthIncrease Factor of 3.5.

Fracture toughness (IF) was 2.3 MPam^(0.5).

Translucence was extraordinary.

Example 9

Glass bars were produced according to example 1. The glass again washomogeneous and transparent.

The first crystallization was performed at 650° C. for a period of 20minutes.

Lithium metasilicate was determined to be the only phase. Biaxialstrength was 112+/−13 MPa.

Again the milling time of a test body was measured. The milling time ofthe test body was one minute below that of ProCAD®, which again was usedas reference.

The edge strength was good.

After a second crystallization which was performed according to example1 the biaxial strength was 356+/−96 MPa which correlates to a StrengthIncrease Factor of 3.16.

Fracture toughness (IF) was 1.9 MPam^(0.5).

Translucence was acceptable.

Example 20 Comparison

Glass bars were produced according to example 1. The glass again washomogeneous and transparent.

The first crystallization was performed at 650° C. for a period of 20minutes.

Lithium disilicate was determined as the main phase and lithiummetasilicate was only present in traces. Biaxial strength was 194+/−35MPa.

Again the milling time of a test body was measured. The milling time ofthe test body was four minutes longer that of ProCAD®, which again wasused as reference.

The edge strength was poor.

After a second crystallization which was performed according to example1 the biaxial strength was 405+/−80 MPa which correlates to a StrengthIncrease Factor of 2.09.

Fracture toughness (IF) was 1.88 MPam^(0.5).

Translucence was very good.

This example makes it even more obvious that in the light of the glassceramic materials according to the invention the adverse properties inrespect to machinability of the prior art material disqualify same to beused in applications as are mentioned above.

The following examples 21 to 23 show the usefulness of the lithiumsilicate glass according to the invention which comprises nucleisuitable for the formation of lithium metasilicate and subsequentlylithium disilicate glass ceramics.

Example 21

A glass melt having the composition according to example 14 was meltedin a platinum crucible at a temperature of 1500° C. for 3 hours. Theglass was not poured in a steel mould, but quenched in water.

Thus, a glass granulate formed which was dryed and subsequently heatedto 500° C. for 30 minutes to produce nuclei suitable for the formationof lithium metasilicate crystals. The obtained glass was milled to aparticle size of less than 45 μm.

The obtained powder was mixed with a modeling liquid consisting of morethan 95% water and additives for improving moldability and layered on acrown cap of densely sintered zirconium oxide, e.g. DCS-zircon.

The crown cap was fired in a dental furnace at a temperature of 900° C.with 2 minutes holding time. By this procedure the applied glass powdercontaining nuclei for the crystallization was simultaneouslycrystallized and densely sintered so that a dentine core of lithiumdisilicate glass ceramic resulted. On this core a suitable incisal masshaving a suitable expansion coefficient was applied.

The final anterior tooth restauration showed good resistance againstrapid temperature changes up to 160° C. This proves a good bond betweenthe dentine layer of lithium disilicate glass ceramic and the frameworkof high-strength zirconium oxide.

Example 22

Bars of a glass having a composition according to example 14 wereprepared in the same manner as in example 1. The glass bars werehomogenous, transparent and light yellow coloured. A crown cap ofdensely-sintered zirconium oxide was circularly reduced. Subsequently adentine core was layered with dental wax and the crown margin wasmodeled on the stump. The restauration was provided with a cast-onchannel. The crown cap was applied on a muffle basis and embedded ininvestment material, (Empress Speed, Ivoclar). After the requiredbinding time the muffle was preheated to 850° C. resulting in theremoval of the wax. After 90 minutes a blank of the above lithiumsilicate glass having nuclei for forming lithium metasilicate was put inthe muffle and pressed on the cap of zirconium oxide in accordance withthe known Empress-hot pressing process at 900° C. This resulted incrystallization of the glass blank to a lithium disilicate glassceramic.

After divesting, the final product was a zirconium oxide cap having adentine layer of lithium disilicate glass ceramic. This dentalrestoration showed an excellent fit of the circular edge on the model.Furthermore, the so-prepared dentine layer was free from porosities.

Example 23

A metal cap of an alloy having an expansion coefficient of 12.8*10⁻⁶ 1/Kand a solidification temperature of 11000° C. was prepared in a castprocess, sand-blasted and by an oxidation-firing step prepared for thefurther processing.

In an analogous manner as in example 22 a dentine core was applied onthe cap using modeling wax. The metal cap was embedded, and the wax wasremoved by firing in a furnace. As in example 22 a blank of the lithiumsilicate glass having suitable nuclei was hot-pressed on the metal capat 900° C.

The so-prepared dental restoration showed a good bond between metalframework and the lithium disilicate glass ceramic and also had a highresistance against drastic temperature changes of above 160° C.

It is a further embodiment of the present invention to provide methodsof mass-production of strong and aesthetic dental restorations usinglithium silicate blanks and at least 4-axis or higher order (more axes)CNC machines. More specifically, this embodiment is related to millingstrategies especially useful for machining lithium silicate blanks using5-axis or higher order computer numerical controlled (CNC) machinesequipped with robotic and automated loading features. The CNC machinecan include a computer (CPU), CNC control unit, memory device and/orsoftware package.

Prior examples describe machining lithium silicate blanks of thisinvention using CEREC (Sirona, Germany) and DCS Precimill (DCS,Switzerland) CAD/CAM systems. While Sirona CEREC in Lab isrepresentative of a compact, bench-top, dental CAD/CAM system capable ofmilling a variety of machinable ceramics and other reasonably weak andsoft materials, DCS Precimill is a much larger and stiffer machine thanCEREC. The DCS Precimill machine can mill much stronger and hardermaterials such as titanium alloys and fully dense zirconia. Bothmachines have been specifically developed as dental CAD/CAM systems forthe dental laboratory environment, each utilizing its own, uniquemilling strategy and tool paths which suffer from a number ofdisadvantages if used for machining lithium disilicate blanks.

It is important to recognize that total per unit fabrication time for agiven CAD/CAM system consists of at least milling time and set-up time(i.e., set up of the machine and the software configuration for each newcase that can include installing a new block and loading a newcase/file). CEREC in Lab is a very efficient system for milling oneblock at a time as it utilizes two grinding tools (diamond burs)simultaneously. The outside surface is machined with a round-tipcylindrical diamond bur at the same time as the inside surface of thedental restoration is machined with a stepped-cylindrical or conical(tapered) diamond bur. As a result, it takes about 25 minutes to mill astandard full-contour molar (which may be defined as an average sizefull contour molar crown of generic design such as tooth #30 on IvoclarVivadent Model #594148) or even less, about 20 minutes, on a new CERECMC XL machine. Nevertheless, manual blank installation and softwarepreparation steps take at least a few minutes noticeably increasingtotal per-unit fabrication time to about 25-30 minutes. It is alsoimportant to note that the Sirona system utilizes fairly small diamondburs with a grit or grain size of less than 60 microns. The resultingbiaxial strength exceeds 300 MPa. The DCS system is a larger machinelacking optimal milling strategies and tool paths for lithium silicateblanks and also is not equipped with robotic/automated loading features,therefore yielding unfavorably large per-unit time if used for millinglithium silicate restorations. As a result, both machines are notoptimal for milling centers and central processing facility environmentsrequiring shorter fabrication times per unit and system capacity forautomation.

Grinding tools may include a diamond coating comprising single crystalor polycrystalline diamonds of a certain grain (grit) size. Grindingtools may include a diamond coating of a certain grit size. The power ofthe grinding tools (i.e., the material removal rate for a given appliedforce and depth of cut) is proportional to the diamond coating grainsize minus the embedding depth of the diamond grains in the bondinglayer. This is discussed in an article by Dmitri Wiebe, Isabella MariaZylla. “Assessment of the Grinding Power and Service Life ofGalvanically Diamond Coated Grinding Tools”. Journal of AppliedResearch, Vol. 7, No. 1, March 2007, pp 138-145.), which is herebyincorporated by reference. Depth of cut, sometimes referred to aslateral lining, is the distance that a tool penetrates into the workpiece on each pass and it often depends on the diamond grain sizedistribution on the tool, which is sometimes characterized by diamondgrit size in microns. Coarser, more even-sized embedded diamond grit,more uniformly distributed in the coating may also allow increasingdepth of cut and easier removal of debris.

Coarser diamond grit size of the grinding/milling tool allows for anincrease in the feed rate and the depth of cut, which results in ahigher material removal rate and a lower milling time. Unfortunately, italso increases surface damage, i.e. the size of surface flaws, whichresults in lower strength. Therefore, a compromise is required betweenmilling time and the minimally acceptable target strength of thematerial based on its clinical indications, i.e., ≧300 MPa for lithiumdisilicate restorations (fixed prostheses) fabricated by heat treatingof milled lithium silicate dental articles, which belong to Type IIClasses 3 and 4 dental ceramics according to ISO6872:2008. This dilemmaseverely limits the productivity of milling centers utilizing existingdental CAD/CAM systems using prior art milling strategies and toolpaths.

Embodiments of the present invention teach milling strategies that allowthe use of coarse diamond milling tools without having to compromise thefinal strength of the milled lithium silicate material, thus allowingfor a reduction in milling time. In order to determine the allowablesize of the diamond grit that may be used for milling dental ceramicblanks, the size of allowable surface and volume critical flaws of thematerial to be machined must be determined.

One example of a preferred material for milling dental articles usingthe strategies herein is lithium silicate. The final flexural strengthand fracture toughness and the respective strength and toughness factorsset forth in Table IV were used to calculate the strength and fracturetoughness of the lithium silicate materials in Examples 1 through 20after the 1^(st) crystallization (also referred to as the “machinablecondition” of the lithium silicate materials for milling or machining,prior to subsequent heat treatment or crystallization steps). Table Vpresents the calculated flexural strength and fracture toughness oflithium silicate materials from Examples 1 through 20 in “machinablecondition” corresponding to data provided in Table IV on final strengthand fracture toughness (after 2^(nd) crystallization), andstrength/fracture toughness increase factors.

TABLE V Flexural Strength Fracture Toughness (σ_(f)), MPa (K_(Ic)), MPa· m^(1/2) Example Machinable Machinable Edge Number Final Condition SIF*Machinability Final Condition TIF** Strength 1 359 120 3.0 very good 1.60.9 1.8 good 2 424 177 2.4 good 2.2 1.3 1.7 very good 3 250 100 2.5 verygood 1.9 0.7 2.6 good 4 314 92 3.4 very good 1.9 0.8 2.5 good 5 324 1352.4 good 1.8 1.1 1.6 good 6 472 135 3.5 very good 2.3 1.0 2.4 good 7 426122 3.5 very good 1.8 0.9 2.0 acceptable 8 404 176 2.3 good 2.4 1.3 1.9good 9 356 111 3.2 very good 1.9 1.0 1.9 acceptable 10 319 118 2.7 verygood 1.8 1.0 1.8 good 11 301 177 1.7 acceptable 2.1 1.3 1.6 good 12 354122 2.9 very good 2 1.1 1.9 acceptable 13 381 127 3.0 very good 1.9 0.92.1 very good 14 389 125 3.1 very good 2 1.1 1.8 very good 15 342 1322.6 very good 1.8 0.9 2.0 very good 16 329 113 2.9 good 1.7 1.1 1.6 verygood 17 420 131 3.2 good 2.1 1.0 2.2 very good 18 387 114 3.4 very good1.9 1.0 1.9 good 19 440 200 2.2 poor 1.8 1.8 1.0 good 20 405 193 2.1poor 1.9 1.3 1.5 good *Strength Increase Factor; **Fracture ToughnessIncrease Factor

The flexural strength and fracture toughness of the lithium silicatematerials in machinable condition (i.e., prior to the secondcrystallization step) were then used to calculate the surface and volumecritical flaw sizes using the Griffith-Irwin equation (Equation 1 below)K _(Ic) =Yσ _(f) c ^(1/2)  {Eq. 1}orC=(K _(Ic) /Yσ _(f))²  {Eq. 2}orσ_(f) =K _(Ic)/(Yc ^(1/2))  {Eq. 3}where

-   -   C is the length of the critical flaw size for surface cracks        (surface failure origin)    -   2C is the length of the critical flaw size for volume cracks        (volume failure origin)    -   K_(Ic) is the fracture toughness or critical stress intensity        factor    -   σ_(f) is the stress at fracture or flexural strength    -   Y is a geometrical factor or constant that depends on the type        of critical flaw, i.e., location, orientation and geometry of        the critical flaw and loading configuration; Y is assumed to be        roughly equal to 1 for pure Mode I fracture (plain strain        loading configuration), 1.24 (semicircular) or 1.94 (shallow        cracks), wherein Y=1 is the maximum critical flaw size.

The Griffith-Irwin equation is discussed in an article by Alvaro DellaBona, John J. Mecholsky Jr., Kenneth J. Anusavice entitled “Fracturebehavior of lithia disilicate- and leucite-based ceramics” in DentalMaterials (2004) 20, pp 956-962, which is hereby incorporated byreference. Geometrical factors given in the aforementioned article byDella Bona et al., allow using flexural strength values to calculatecritical flaw sizes for different crack configurations based on knownfracture toughness values. According to Equation 3 above, the larger thegeometric factor (Y) the more dangerous, more strength limiting thisparticular flaw/loading configuration is, resulting in lower finalflexural strength values or even failure of the part during milling.

Table VI sets forth surface and volume critical flaw sizes calculatedusing the equation above (Equation 1) from flexural strength andfracture toughness values of Table V and geometrical factor values (Y).

TABLE VI Properties of lithium silicate blanks in Critical Surface FlawSize, Critical Volume Flaw Size, machinable σ_(f), K_(Ic), micronsmicrons condition MPa MPa · m^(1/2) shallow semi- plain shallow plainCrack Type/Configuration cracks circular strain cracks circular strainExample No. Y = 1.94 Y = 1.24 Y = 1 Y = 1.94 Y = 1.24 Y = 1 1 120 0.9 1536 55 29 72 110 2 177 1.3 14 35 54 29 70 107 3 100 0.7 14 35 53 28 69107 4 92 0.8 18 44 68 36 88 135 5 135 1.1 18 45 69 37 90 139 6 135 1.013 33 50 27 66 101 7 122 0.9 15 36 55 29 71 109 8 176 1.3 14 34 52 27 67103 9 111 1.0 21 53 81 43 105 162 10 118 1.0 19 47 72 38 93 143 11 1771.3 15 36 55 29 71 110 12 122 1.1 20 48 74 40 97 149 13 127 0.9 13 33 5127 66 102 14 125 1.1 21 51 78 42 102 157 15 132 0.9 12 30 47 25 61 94 16113 1.1 23 57 88 47 114 175 17 131 1.0 14 34 53 28 69 106 18 114 1.0 2150 77 41 100 154 19 200 1.8 22 53 81 43 105 162 20 193 1.3 11 28 43 2323 86

Reference is made to FIG. 8, which shows a block of material 80undergoing a milling process with a diamond grinding tool 82. Diamondtool 82 has a plurality of diamond grains 86 embedded in tool 82. FIG. 8illustrates the relation of the diamond grain size or diamond grit andthe embedding depth of the diamond grains in the bonding layer to theoptimum depth of cut and scratch/surface flaw size. Block 80 is milledlayer by layer, the depth of cut 84, also known as lateral lining, isthe thickness of the layer being removed and/or the distance the toolpenetrates the block on each pass of debris 87 being removed from block80. Although there is no limitation on the thickness of the layer beingremoved, it is preferable that the thickness of the layer being removedon each pass (lateral lining) or depth of cut be less than the diamondgrain size (grit size) in the range of approximately 10 to approximately130 microns, and preferably in the range of approximately 20 toapproximately 100 microns. A flaw 89 is shown in block 80. The flaws orscratches on block 80 resulting from milling with tool 82 may correlatewith the distribution, size, shape, orientation or the variability ofembedding depth of the diamond grains in the bonding layer of tool 82.It is possible that the scratches, crevices and other flaws left bygrinding tool on the machined surface will scale with the diamond gritsize or size of the diamond grains 86 embedded in tool 82. That is, thesize of the deepest flaws that can potentially result in failure of thedental article during milling or post-fabrication (i.e. critical flaws)will be at least a fraction of the diamond grit size in microns or, inworst case scenario, can be nearly equal to the diamond grit size.

Conventional wisdom teaches that grinding power of a tapered tool isgenerally lower than that of cylindrical tool, as also discussed inWiebe et al., referenced above.

Conventional wisdom also teaches that diamond grit size (see FIG. 8 anddiscussion above) should not exceed the estimated maximal criticalsurface flaw size. For lithium silicate, based on the data in Table VI,that would be approximately 60 microns for lithium silicate, the averageof the values set forth in Table VI for critical surface flaw size whenY=1. It appears that diamond tool selection for Sirona's CEREC machines,discussed above, was based on this conventional wisdom.

Surprisingly, it was found by the inventors herein that certain shapesof tapered diamond tools combined with certain milling strategiesdesigned preferably for use with 5-axis or higher order milling machineswould allow use of much coarser (by a factor of 1.5-2.5) diamond grit.In the milling strategies and processes herein, the size of the diamondgrains (grit size) on the diamond tools may be in the range between theestimated maximal critical surface flaw size and the estimated maximalcritical volume flaw size. This drastically accelerates the millingprocess without noticeable compromise in strength. Reference is made toTable VI wherein the estimated maximal critical surface flaw size of thelithium silicate ceramic is approximately 60 microns (column 6 of TableVI where Y=1) and the estimated maximal critical volume flaw size isapproximately 130 (column 9 of Table VI where Y=1). Accordingly, thesize of the diamond grit may range from approximately 40 toapproximately 175 microns for the diamond grinding tools for the lithiumsilicate ceramic blocks, preferably in the range of approximately 60 toapproximately 150 microns and most preferably in the range ofapproximately 90 to approximately 130 microns. The strategies describedherein are in no way limited to lithium silicate materials and may beapplied to all types of ceramic materials, preferably medical ceramicmaterials and most preferably dental ceramic materials.

The shapes of the diamond burs are preferably conical with rounded tips(tapered round) as shown in FIGS. 9, 10 and 11. In comparison thereto,the Sirona tools used in the CEREC systems are shown in FIGS. 12 and 13.Comparing the tools used herein (FIGS. 9, 10 and 11) with those used inthe Sirona CEREC system (FIGS. 12 and 13), one can see that the diamondgrit of the tools used herein, is noticeably larger and substantiallyequiaxed. For example, in FIG. 9, a diamond grain 100 is nearly aperfect hexagon.

FIGS. 14 a, b, and c, 15 a, b, and c and 16 a, b, and c show examples ofspecific configurations and dimensions of the tools used herein. Theembodiments of the invention are not limited to the sizes and shapesshown herein. FIGS. 14 a, b, and c show an example of a tool 140 that isuseful for milling the interior or the inside of the article. Tool 140has a diamond grit (grain size) of approximately 126 microns. FIGS. 15a, b, and c show a tool 150 that is useful for milling the exterior oroutside of the article. Tool 150 has a diamond grit (grain size) ofapproximately 91 microns. FIGS. 16 a, b, and c show a tool 160 that isuseful for finishing the milling of the article. Tool 160 has a diamondgrit of approximately 91 microns in diameter. Moreover, tool 160 alsohas a much finer point, the tip is approximately 0.5 mm in diameter incomparison to the tips of the tools shown in FIGS. 14 (tip isapproximately 1.3 mm) and 15 (tip is approximately 1.2 mm). These toolsare useful in maintaining accuracy and marginal integrity of the articleduring the milling process.

In addition to the tool size and diamond grit size, the millingstrategies include fine, intermediate and rough machining steps. Therough, intermediate and fine milling may be dependent on a variety offactors including, but not limited to, tool specifications, revolutionsper minute, linear speeds, feed rate (mm/min), feed per rotation(microns), depth of cut and material removal rate.

The milling strategies discussed herein may be combined with roboticfeatures (“6^(th) axis”) of heavy duty industrial CNC machines to enablecost-effective use of such high productivity (and expensive) industrialCNC machines. These machines are equipped with robotic and automatedloading features that were previously cost-prohibitive for dental use.

Specific illustration of milling strategies and milling parameters ofembodiments of the present invention are presented in the nonlimitingexamples below carried out using Roeders (Röders) 5-axis CNC machines(ROEDERS GmbH, Germany). Two Roeders models were used: RXP 500 DS modelwith 42,000 RPM and RXD5 model with 50,000 RPM. These Roeders 5-axis CNCmachines are characterized by a very fast control unit capable of feedrates of up to 40,000 mm/min with a high capacity for automation. Itshould be mentioned that the actual feed rate of the milling process isdependent on the machine, tooling and material being milled. Normally in5 axis milling, the CNC control unit is not able to calculate the xyzpoints for a constant speed. If the surface is very complex (fullanatomical crown) the machine is not always capable of maintaining thedefined speed. Röders has a very fast CNC control unit, but it is stillnot always constant in speed. The control unit and the motors make thebig difference in accuracy and milling time. In addition to a computer,CNC control unit, memory device and software package, the followingTable VII lists additional properties of the system.

TABLE VII CAD/CAM SYSTEM PROPERTIES Block processing time <0.1 ms Lookahead window with more than 10,000 blocks Calculation of optimal feedrates and accelerations by taking into account the cutter path geometryand machine dynamics in order to achieve the highest possible accuracyand shortest machining time 5 axes simultaneously Automatic splineinterpolation for outstanding dynamics; it is possible to set thetolerance values User-defined jerk limitation ==> adjustable dynamicsfor high accuracy or extremely short machining times Smoothening of thecutter path with tolerance specification for reducing the machining timeby up to 35% Automatic compensation of the rotations of the 4th and 5thaxes for the cutter center or cutter tip (TCP) is possible Compensationof the spindle elongation in the control carried out either by a highlyaccurate measurement sensor or the by the software 3D radius cuttercompensation for milling programs with normal vectors Modern computertechnology Parallel computer system with PC based hardware Highprocessor performance and large hard drive capacity CD-ROM drive isstandard; other drives are available on request Standard 15″ TFT monitorStandard Universal network interface Connection to the telephone networkpossible to enable remote diagnosis Job management Clearly structuredjob management for individual work pieces with corresponding programs;can also be used for multiple clamping in machines without robots Iftool breakage is detected, the current job is stopped and the next jobof the job list is started Interactive priority list with job and workpiece parameters A robot interface for automation with various types ofrobot systems is available Integration of pallet identification withchips possible Interfaces to job management and planning software ofwork shop available

The following examples illustrate the embodiments of the presentinvention directed to milling lithium silicate blanks using CNC machinesintegrated with dental CAD systems for automated fabrication of dentalrestorations known as dental CAD/CAM systems.

Examples 24 and 25

The shape to be milled was mapped onto a blank to establish the volumeto be removed, which was separated into regions requiring differentaccuracy and surface roughness. The regions were allocated to one ormore of a rough machining, intermediate machining and fine machiningstep. The specific tool path was calculated for each of the allocatedmachining steps. CAM file was generated using DentMILL-3-5 Axis DentalCAM software from DELCAM (Birmingham, UK). This software has sometemplates available for milling zirconia, titanium and non-preciousalloys but not for lithium silicate or any other glass-ceramics.Therefore the custom template was configured based on the principalsdescribed above. The machines used in these examples were the RoedersRXP500 DS model capable of 42,000 RPM and the Roeders RXD5 model capableof 50,000 RPM. The dental article milled in Example 24 was a centralcrown and included 9 machining steps. Example 25 was a molar crown andmilling included 8 machining steps. The following Tables VIII and IX setforth the machining steps and their essential characteristics.

TABLE VIII Example 24 Central Crown Program Tool Feed per Feed ToolDiamond Depth revolution, Order of Rate, F Diameter Grit of Cut micronsMachining Steps Execution mm/min mm microns microns RXP500/RXD5Drilling_inside_1_1.TAP 1 (R) 1500 1.3 126 50 36 30Milling_inside_2_1.TAP 2 (R) 2000 1.3 126 80 48 40Prep_rough1_inside_3_1.TAP 3 (R) 2000 1.3 126 100 48 40Prep_rough1_outside_4_1.TAP 4 (R) 2000 1.3 126 100 48 40Drilling_outside_5_1.TAP 5 (R) 1500 1.3 126 70 36 30 Prep_semi_6_1.TAP 6(I) 1000 1.2 91 40 24 20 Prep_fini_7_1.TAP 7 (F) 3000 0.5 91 22 71 60Milling_outside_8_1.TAP 8 (I) 1500 1.2 91 40 36 30Milling_outside_9_1.TAP 9 (I) 1500 1.2 91 65 36 30 R - rough machining,I - intermediate machining, F - fine machining

TABLE IX Example 25 Molar Crown Program Tool Feed per Feed Tool DiamondDepth revolution, Order of Rate, F Diameter Grit of Cut micronsMachining Steps Execution mm/min mm microns microns RXP500/RXD5Drilling_inside_1_1.TAP 1 (R) 1500 1.3 126 50 36 30Milling_inside_2_1.TAP 2 (R) 2000 1.3 126 80 48 40Prep_rough1_inside_3_1.TAP 3 (R) 2000 1.3 126 100 48 40Prep_rough1_outside_4_1.TAP 4 (R) 2000 1.3 126 100 48 40Drilling_outside_5_1.TAP 5 (R) 1500 1.3 126 70 36 30 Prep_semi_6_1.TAP 6(I) 1000 1.2 91 40 24 20 Prep_fini_7_1.TAP 7 (F) 3000 0.5 91 22 71 60Milling_outside_8_1.TAP 8 (I) 1500 1.2 91 70 36 30 R - rough machining,I - intermediate machining, F - fine machining

In the examples shown, the target accuracy of the margin at thepreparation line was very high, within about 25 microns. Therefore, twomachining steps, 6^(th) and 7^(th), were carried out internally toprovide higher accuracy at the preparation line. The depth of cut(lateral lining) ranged from approximately 0.022 mm (22 microns) toapproximately 0.10 mm (100 microns) for the two examples. To quantifyaccuracy, the milled parts were scanned with Renishaw Cyclon Scannerwith an accuracy of 3 microns and the scan was compared with thecorresponding CAD file in STL format using Geomagic® QUALIFY software.The accuracy (standard deviation) was measured to be 0.022 mm (22microns).

Example 26

Example 26 illustrates the use of the “6-th axis” or loading robotattached to 5-axis CNC machine. A blank or block holder 22 is attachedto a pallet having a transponder such as a radio-frequencyidentification (RFID) tag for providing information about the millblock, such as type of material, shade, strength, and other factorsuseful about the material. A sensor on the milling machine reads theRFID tag to determine the material on the pallet prior to the millingoperation. A database linked to the milling machine associates aspecific CAM file to the block of material and the machine mills theblock in accordance with the CAM file. A pallet carrying a mill block isplaced on a shelf of an automatic loading system from which it isautomatically transferred to the housing of the CNC machine when theassociated CAM file comes up for execution in the job queue. Suchautomated loading system can carry from hundred or less to few hundredsand even thousands units. This robotic feature is sometimes called“sixth axis”.

When a new block is added to the holder and pallet, the informationregarding the properties of the block of material may be input by anoperator by the use of a barcode type scanner. The RFID tag is scannedand the control panel is programmed to erase the prior informationassociated with the previous block of material. The new materialinformation is then entered into the control panel. A database storesthe information about the block of material on the pallet. When a newcase is ready to be milled, the CAM file associated with the block onthe pallet is utilized to mill the block accordingly. Such automatedloading/robotic system, available only for larger, industrial CNCmachines noticeably shortens per unit fabrication time.

Although the present invention has been described in connection withpreferred embodiments thereof, it will be appreciated by those skilledin the art that additions, deletions, modifications, and substitutionsnot specifically described may be made without department from thespirit and scope of the invention as defined in the appended claims.

1. A method of machining a lithium silicate dental ceramic into a dentalarticle with fabrication time under about 30 minutes per unit, whereinthe fracture toughness (K_(Ic)) and the flexural strength (σ_(f)) of thedental ceramic material are known, comprising: calculating an estimateof the maximal surface critical flaw size and an estimate of the maximalvolume critical flaw size of the dental ceramic using the followingformula:c=(K _(Ic)/σ_(f))² wherein: c is the maximal surface critical flaw sizeand 2c is the maximal volume critical flaw size; implementing amachining strategy using a series of diamond tools, wherein the diamondtools comprise embedded diamonds; wherein the machining strategycomprises rough, intermediate and fine machining steps; wherein eachstep comprises a tool path and machining parameters, wherein the toolpath and machining parameters are carried out by at least one of theseries of diamond tools; wherein the grain size of the embedded diamondsis larger than approximately the estimated maximal size of the surfacecritical flaw and smaller than approximately the estimated maximal sizeof the volume critical flaw.
 2. The method of claim 1 wherein themachining is conducted on a 5-axis or higher order computer numericalcontrolled (CNC) machine, wherein the CNC machine comprises a computer(CPU), CNC control unit, memory device and/or software package.
 3. Themethod of claim 1 wherein machining comprises grinding, drilling,milling or a combination thereof.
 4. The method of claim 1 wherein thedental ceramic blank comprises lithium silicate having a strength in therange from approximately 80 to approximately 180 MPa and a fracturetoughness in the range from approximately 0.7 to approximately 1.3MPa·m^(0.5).
 5. The method of claim 4 wherein the grain size of theembedded diamonds is from approximately 60 to approximately 150 microns.6. The method of claim 5 wherein the grain size of the embedded diamondsis from approximately 90 to approximately 130 microns.
 7. The method ofclaim 1 wherein the machining parameters comprise tool specifications,revolutions per minute, linear speeds, feed rate, feed per rotation,depth of cut and material removal rate.
 8. The method of claim 7 whereinthe depth of cut is smaller than the grain size of the embeddeddiamonds.
 9. The method of claim 8 wherein the feed per rotation issmaller than the depth of cut.
 10. The method of claim 9 wherein thedepth of cut is smaller than the estimated maximal value of the surfacecritical flaw size for fine machining and larger than the estimatedmaximal value of the surface critical flaw size for rough machining. 11.The method of claim 1 wherein the series of tools comprise conicaldiamond tools with a round tip having diamond grains of different size.12. The method of claim 1 wherein the rough, intermediate and finemachining steps are dependent on the grain size of the embeddeddiamonds.
 13. The method of claim 12 wherein the dental ceramic blank ismachined into a dental article having a net shape and wherein the rough,intermediate and fine machining steps are further dependent on thedifference in volume of the dental ceramic blank and the machined netshape of the dental article and further dependent on the final roughnessand accuracy of the machined net shape.
 14. The method of claim 1wherein the flexural strength is selected from the group consisting offlexural strength per ISO6872, 3-point bend strength, 4-point bendstrength, biaxial flexure strength.
 15. The method of claim 1 whereinselection of the series of diamond tools and machining steps reducemachining time while maintaining strength, accuracy and marginalintegrity.
 16. The method of claim 15 wherein machining is conducted ona computer numerical controlled (CNC) machine, and wherein the accuracyis measured using the CNC machine after machining, wherein the accuracyis within 25 microns or less.
 17. A dental article fabricated from adental ceramic blank using an industrial CNC machine and optimalmachining strategy, wherein the fracture toughness (K_(Ic)) and theflexural strength (σf) of the dental ceramic material are known, thedental article fabricated by a process comprising: calculating anestimate of the maximal surface critical flaw size and an estimate ofthe maximal volume critical flaw size of the dental ceramic using thefollowing formula:c=(K _(Ic)/σ_(f))² wherein c is the maximal surface critical flaw sizeand 2c is the maximal volume critical flaw size; determining the numberof machining steps needed to mill the dental ceramic blank into thedental article, wherein each machining step comprises rough,intermediate and/or fine machining, at least one tool path and machiningparameters; using at least one of a series of diamond tools for eachmachining step, wherein the diamond tools comprise embedded diamonds;wherein the grain size of the embedded diamonds is larger thanapproximately the estimated maximal size of the surface critical flawand smaller than approximately the estimated maximal size of the volumecritical flaw.
 18. The dental article of claim 17 wherein the dentalarticle comprises an inside surface, an outside surface and apreparation line and wherein the machining steps comprise one or more ofthe following: drilling inside the ceramic blank, milling inside theceramic blank, milling the preparation line inside the ceramic blank,milling the preparation line outside the ceramic blank, drilling outsidethe ceramic blank, and milling outside the ceramic blank.
 19. The dentalarticle of claim 17 wherein the tool diameters range from approximately0.5 mm to approximately 3.0 mm.
 20. The dental article of claim 17wherein the grain size of the embedded diamonds range from approximately60 microns to approximately 150 microns.
 21. The dental article of claim20 wherein the grain size of the embedded diamonds range fromapproximately 90 microns to approximately 130 microns.
 22. The dentalarticle of claim 17 wherein the machining parameters comprise toolspecifications, revolutions per minute, linear speeds, feed rate, feedper revolution, depth of cut and material removal rate.
 23. The dentalarticle of claim 22 wherein the feed rate ranges from approximately 500mm/min to approximately 5000 mm/min.
 24. The dental article of claim 22wherein the depth of cut ranges from approximately 10 microns toapproximately 130 microns.
 25. The dental article of claim 17 whereinthe dental ceramic blank comprises lithium silicate having a strength inthe range from approximately 80 to approximately 180 MPa and a fracturetoughness in the range from approximately 0.7 to approximately 1.3MPa·m^(0.5).
 26. The dental article of claim 25 wherein the strength isin the range from approximately 90 to approximately 150 MPa.
 27. Thedental article of claim 17 wherein a first computer file comprises thespecifications of the dental article and wherein the tool path isdetermined from the specifications in the first computer file.
 28. Thedental article of claim 27 wherein the dental ceramic blank comprises ageometry and material properties and wherein the specifications of thefirst computer file are compared with the geometry and materialproperties of the dental ceramic blank.
 29. The dental article of claim28 further comprising mapping the specifications of the first computerfile onto the dental ceramic blank to determine the volume of materialto be removed, separating the volume of material to be removed intoregions comprising degrees of accuracy and surface roughness.
 30. Thedental article of claim 29 wherein the regions are machined by roughmachining, intermediate machining and/or fine machining steps.
 31. Thedental article of claim 30 wherein each rough, intermediate and finemachining step comprises at least one tool path, machining parametersand tool selection.
 32. The dental article of claim 31 wherein the toolpath is calculated and converted into a series of commands in a secondcomputer file.
 33. The dental article of claim 32 wherein the secondcomputer file, machining parameters and tool selection are provided to amilling machine.
 34. The dental article of claim 17 wherein the dentalarticle comprises an inlay, an onlay, an overlay, a bridge, an abutment,a facing, a veneer, a facet, a crown, a partial crown, a framework or acoping.
 35. The dental article of claim 17 wherein the dental ceramicblank comprises a ceramic that may be heat treated after machining toincrease the strength and/or the fracture toughness.
 36. The dentalarticle of claim 35 wherein the increased strength is equal to orgreater than approximately 250 MPa.
 37. The dental article of claim 35wherein the increased fracture toughness is equal to or greater thanapproximately 1.5 MPam^(0.5).
 38. The dental article of claim 17 whereinthe dental ceramic blank comprises SiO₂, Li₂O, and P₂O₅.
 39. The dentalarticle of claim 38 wherein the dental ceramic blank further comprisesone or more of K₂O, Al₂O₃, ZnO, Na₂O, ZrO₂, Me^(II)O, and acoloring/fluorescent metal oxide.
 40. The dental article strategy ofclaim 39 wherein the Me^(II)O comprises CaO, BaO, SrO, MgO or a mixturethereof.
 41. The dental article of claim 40 wherein thecoloring/fluorescent metal oxide comprises an oxide of Ta, Tb, Y, La,Er, Pr, Ce, Ti, V, Fe, Mn or a mixture thereof.